Abstract

To develop further understanding towards the role of a heterogeneous microstructure on tensile crack initiation and failure behavior in chopped carbon fiber chip-reinforced composites, uni-axial tensile tests are performed on coupons cut from compression molded plaque with varying directions. Our experimental results indicate that failure initiation is relevant to the strain localization, and a new criterion with the nominal modulus to predict the failure location is proposed based on the strain analysis. Furthermore, optical microscopic images show that the nominal modulus is determined by the chip orientation distribution. At the area with low nominal modulus, it is found that chips are mostly aligning along directions transverse to loading direction and/or less concentrated, while at the area with high nominal modulus, more chips are aligning to tensile direction. On the basis of failure mechanism analysis, it is concluded that transversely-oriented chips or resin-rich regions are easier for damage initiation, while longitudinally-oriented chips postpone the fracture. Good agreement is found among failure mechanism, strain localization and chip orientation distribution.

@article{osti_1431183,
title = {Correlation between failure and local material property in chopped carbon fiber chip-reinforced sheet molding compound composites under tensile load},
author = {Tang, Haibin and Chen, Zhangxing and Zhou, Guowei and Li, Yang and Avery, Katherine and Guo, Haiding and Kang, Hongtae and Zeng, Danielle and Su, Xuming},
abstractNote = {To develop further understanding towards the role of a heterogeneous microstructure on tensile crack initiation and failure behavior in chopped carbon fiber chip-reinforced composites, uni-axial tensile tests are performed on coupons cut from compression molded plaque with varying directions. Our experimental results indicate that failure initiation is relevant to the strain localization, and a new criterion with the nominal modulus to predict the failure location is proposed based on the strain analysis. Furthermore, optical microscopic images show that the nominal modulus is determined by the chip orientation distribution. At the area with low nominal modulus, it is found that chips are mostly aligning along directions transverse to loading direction and/or less concentrated, while at the area with high nominal modulus, more chips are aligning to tensile direction. On the basis of failure mechanism analysis, it is concluded that transversely-oriented chips or resin-rich regions are easier for damage initiation, while longitudinally-oriented chips postpone the fracture. Good agreement is found among failure mechanism, strain localization and chip orientation distribution.},
doi = {10.1002/pc.24767},
journal = {Polymer Composites},
number = ,
volume = ,
place = {United States},
year = {2018},
month = {2}
}

Compression molded SMC composed of chopped carbon fiber and resin polymer which balances the mechanical performance and manufacturing cost presents a promising solution for vehicle lightweight strategy. However, the performance of the SMC molded parts highly depends on the compression molding process and local microstructure, which greatly increases the cost for the part level performance testing and elongates the design cycle. ICME (Integrated Computational Material Engineering) approaches are thus necessary tools to reduce the number of experiments required during part design and speed up the deployment of the SMC materials. As the fundamental stage of the ICME workflow, commercial softwaremore » packages for SMC compression molding exist yet remain not fully validated especially for chopped fiber systems. In this study, SMC plaques are prepared through compression molding process. The corresponding simulation models are built in Autodesk Moldflow with the same part geometry and processing conditions as in the molding tests. The output variables of the compression molding simulations, including press force history and fiber orientation of the part, are compared with experimental data. Influence of the processing conditions to the fiber orientation of the SMC plaque is also discussed. It is found that generally Autodesk Moldflow can achieve a good simulation of the compression molding process for chopped carbon fiber SMC, yet quantitative discrepancies still remain between predicted variables and experimental results.« less

We present that the introduction of carbon fiber reinforced polymer (CFRP) composites to structural components in lightweight automotive structures necessitates an assessment to evaluate that their crashworthiness dynamic response provides similar or higher levels of safety compared to conventional metallic structures. In order to develop, integrate and implement predictive computational models for CFRP composites that link the materials design, molding process and final performance requirements to enable optimal design and manufacturing vehicle systems for this study, the dynamic mechanical response of unidirectional (UD) and 2x2 twill weave CRFP composites was characterized at deformation rates applicable to crashworthiness performance. Non-standardized specimenmore » geometries were tested on a standard uniaxial frame and an intermediate-to-high speed dynamic testing frame, equipped with high speed cameras for 3D digital image correlation (DIC). Specimen cross-sections, according to each fiber orientation tested, were consistent across strain rates to ensure results were comparable. Tensile strength and modulus were experimentally investigated over a wide range of strain rates (0.0001 to 200 s -1). DIC was used to estimate strain profiles on composites surfaces, and the modulus was calculated from those strain measurements. Experimental results demonstrated an increase in the tensile strength of UD CFRP composites in the longitudinal (0°) and transverse (90°) direction with increasing strain rates. In contrast, the tensile strength of 2x2 woven composites and the tensile modulus of the UD material were insensitive to increasing strain rates. Finally, comparison of failure modes provided insights on how loading rates influenced failure mechanisms.« less

Here, the fatigue damage behavior of chopped carbon fiber chip-reinforced composite has been experimentally and numerically investigated. A large scatter is exhibited in the S-N diagram due to the random distribution of carbon fiber chips, and therefore a new analysis procedure is proposed to link the local microstructure to the fatigue behavior of the bulk material. Interrupted fatigue tests are also performed so that microstructure characterization can be conducted on the tested samples to analyze the crack initiation and propagation. Inspired from the experimental findings, a multi-scale progressive damage fatigue model is proposed to predict the fatigue behavior. The modelmore » incorporates a new stochastic chip-packing algorithm for microstructure reconstruction along with continuum damage models into the representative volume element (RVE) model in ABAQUS/Explicit. Finally, the simulation results based on the proposed model are in good agreement with the experimental data in terms of cracking modes and predicted life.« less

Fiber-reinforced polymer composites are strong candidates for structural materials to replace steel and light alloys in lightweight vehicle design because of their low density and relatively high strength. In the integrated computational materials engineering (ICME) development of carbon fiber composites, microstructure reconstruction algorithms are needed to generate material microstructure representative volume element (RVE) based on the material processing information. The microstructure RVE reconstruction enables the material property prediction by finite element analysis (FEA)This paper presents an algorithm to reconstruct the microstructure of a chopped carbon fiber/epoxy laminate material system produced by compression molding, normally known as sheet molding compounds (SMC).more » The algorithm takes the result from material’s manufacturing process as inputs, such as the orientation tensor of fibers, the chopped fiber sheet geometry, and the fiber volume fraction. The chopped fiber sheets are treated as deformable rectangle chips and a random packing algorithm is developed to pack these chips into a square plate. The RVE is built in a layer-by-layer fashion until the desired number of lamina is reached, then a fine tuning process is applied to finalize the reconstruction. Compared to the previous methods, this new approach has the ability to model bended fibers by allowing limited amount of overlaps of rectangle chips. Furthermore, the method does not need SMC microstructure images, for which the image-based characterization techniques have not been mature enough, as inputs. Case studies are performed and the results show that the statistics of the reconstructed microstructures generated by the algorithm matches well with the target input parameters from processing.« less

Predicting the mechanical behavior of the chopped carbon fiber Sheet Molding Compound (SMC) due to spatial variations in local material properties is critical for the structural performance analysis but is computationally challenging. Such spatial variations are induced by the material flow in the compression molding process. In this work, a new multiscale SMC modeling framework and the associated computational techniques are developed to provide accurate and efficient predictions of SMC mechanical performance. The proposed multiscale modeling framework contains three modules. First, a stochastic algorithm for 3D chip-packing reconstruction is developed to efficiently generate the SMC mesoscale Representative Volume Element (RVE)more » model for Finite Element Analysis (FEA). A new fiber orientation tensor recovery function is embedded in the reconstruction algorithm to match reconstructions with the target characteristics of fiber orientation distribution. Second, a metamodeling module is established to improve the computational efficiency by creating the surrogates of mesoscale analyses. Third, the macroscale behaviors are predicted by an efficient multiscale model, in which the spatially varying material properties are obtained based on the local fiber orientation tensors. Our approach is further validated through experiments at both meso- and macro-scales, such as tensile tests assisted by Digital Image Correlation (DIC) and mesostructure imaging.« less